PTC Heating Element, Electric Heating Device and Use of a PTC Heating Element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
PTC heating elements in electric vehicles face challenges in achieving efficient heat transfer and insulation due to the opposing requirements of thermal and electrical considerations, leading to compromised power density, thermal agility, and reliability, especially when operating at high voltages and requiring insulation to prevent electrical flashovers.
Innovation Solution
A compact PTC heating element design featuring multiple PTC elements with a temperature-resistant filler material, a high-thermal-conductivity carrier layer for mechanical stabilization and insulation, and strategically arranged electrodes and contacts to optimize heat extraction and electrical insulation, allowing for efficient heat transfer and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrically insulating barrier is introduced to prevent electrical flashovers in high-voltage systems, then electrical insulation and reliability are improved, but thermal conductivity and heat transfer efficiency deteriorate
Solution Approach 1:
The patent introduces a dual-layer insulating structure where a first electrically insulating layer (with higher thermal conductivity) is positioned between the PTC element and heat sink, and a second electrically insulating layer (with lower thermal conductivity) is positioned between the conductor track and the first layer. This intermediary layered approach enables both electrical insulation and improved thermal transfer compared to conventional single-layer insulation.
2Productivity
If the PTC element thickness is reduced to improve thermal agility and power density, then heat transfer speed and power density are improved, but manufacturing precision and handling difficulty worsen
Solution Approach 1:
The patent employs a composite layered structure consisting of the PTC element, conductor track, first electrically insulating layer, and second electrically insulating layer. This composite design allows the thin PTC element to be integrated with supporting and insulating layers, enabling reduced thickness for improved thermal agility while the composite structure as a whole maintains manufacturability and handling feasibility.
3Device complexity
If a conventional single-layer insulating structure is used, then device complexity is reduced, but thermal transfer efficiency and power density deteriorate
Solution Approach 1:
The patent applies different insulating materials with different thermal conductivity properties to different locations within the insulation structure. The first electrically insulating layer uses a material with higher thermal conductivity for optimal heat transfer, while the second layer uses a material with lower thermal conductivity. This local differentiation of material properties optimizes thermal transfer efficiency while maintaining electrical insulation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves faster and more efficient heating, reduces power consumption, and enhances the range of electric vehicles by improving power density, thermal response, and reliability while minimizing material usage and ecological footprint.
Implementation Method 1
The PTC element itself acts as a heat source when Joule's heat is generated by energization
Implementation Method 2
an electrical insulating layer is provided which abuts the outside of at least one of the conductive tracks via which the PTC element is energized and comprises a foil and an electrically insulating compound with good thermal conductivity applied thereto
Data Source
AI summary
A PTC heating element for an electric heater having a PTC element, an electrode formed on a surface of the PTC element for electrically contacting the PTC element, at least one additional contact for electrically connecting the electrode of the PTC element, and a carrier layer. The carrier layer is electrically insulating, the thickness of the PTC element is ≤500 μm, and the installation height of the PTC heating element is between 500 μm and 2500 μm. Also disclosed is an electric heater and use of the PTC heating element in a motor vehicle.